Double walled beverage container and method of making same

ABSTRACT

A double walled container is provided for insulating a beverage. An outer insulating shell or container is secured to the inner container that holds the beverage. A gap exists between the outer container and inner container and the air in the gap acts as an insulating barrier. The inner container is preferably a standard aluminum container. The outer container is preferably made from aluminum or a plastic polymer.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 12/986,042, filed on Jan. 6, 2011, which is adivision of U.S. patent application Ser. No. 11/622,995 filed on Jan.12, 2007 now issued as U.S. Pat. No. 7,882,975 on Feb. 8, 2011, each ofwhich are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to beverage containers, and moreparticularly, to a double walled beverage container that enhances theability of the container to maintain the beverage therein at a desiredtemperature.

BACKGROUND OF THE INVENTION

Aluminum beverage containers are perhaps the most widely used containerto hold a number of different types of beverages. There are manyadvantages of using an aluminum container, including ease in manufactureand low relative cost. However, one distinct disadvantage of an aluminumcontainer is its inability to insulate the contents of the container.

It is well known that aluminum containers must be refrigerated if thebeverage therein is to be served cold. Additionally, even if thebeverage is refrigerated immediately prior to consumption, thetemperature of the beverage will quickly warm by contact of theconsumers hand with the container.

One remedy for providing some insulation for the cooled beverage withinthe aluminum container is to place an insulating outer container overthe container. These outer containers are typically made from a type ofresilient foam. The exterior circumference of the outer container isconsiderably larger than the circumference of the container. The outercontainer is removed from the container when the beverage has beenconsumed. Although these simple foam outer containers may be adequatefor their intended purpose, there is a need to provide an insulatedcontainer that does not substantially change the size or shape of thecontainer when held by a consumer. There is also a need to provide acontainer with an integral insulating feature that does not require aseparate device like a foam outer container to be secured thereto.Additionally, there is a need to provide an insulated beverage containerthat is still simple and cost effective to manufacture, and maintainsconsumer appeal when the insulated beverage container is displayed forsale.

SUMMARY OF THE INVENTION

In accordance with the present invention, an insulated beveragecontainer is provided in the form of a double walled container. Thedouble walled container includes a standard aluminum beverage containerin combination with an outer container that substantially conforms tothe shape of the inner aluminum container. Preferably, the outercontainer also is made from aluminum.

In a first embodiment of the present invention, the double walledcontainer of the present invention comprises a standard aluminumcontainer with an outer container or shell that surrounds the sidewallsand base of the aluminum container. The outer container or shell has acomplementary shape, and the dome of the inner aluminum container nestswithin a dome of the outer container. A small gap is maintained betweenthe sidewalls of the inner container and the outer container, and thisgap provides an insulating air space that helps to maintain thetemperature of the beverage. Instead of a nesting configuration betweenthe domes of the inner container and the outer container, thecircumferential leg or protrusion on the base of the inner container mayrest on the dome of the outer container. In this arrangement, a greatergap is provided between the sidewalls of the inner container and outercontainer.

Additional features of the present invention include annular groovesthat may be formed on the outer container to assist in gripping thecontainer. Additionally, for the embodiment including the outercontainer made of a polymer, the color and finish of the polymer may bechosen to enhance the graphics used on the inner container.

Additionally, debossing or embossing the outer container member mayfurther enhance visual features of the inner container graphics.

While simply providing an air gap between the inner container and outercontainer may be adequate for insulating most beverages, it is alsocontemplated that the gap may be filled with an insulating material,such as polyurethane foam, to provide enhanced insulation. Additionally,material placed in the gap may further strengthen the container toprevent undesirable bending of the outer container if the outercontainer is firmly grasped by the consumer. Other materials that can beused to fill the gap between the inner container and outer containerinclude closed cell foam, polystyrene, and corrugated cardboard.Additionally, a selected inert gas may be used to fill the gap, sincesome inert gases have better insulative capability as compared to air.

Also in accordance with the present invention, a method is provided formanufacturing a double walled container. For the manufacture of theinner aluminum container, it may be constructed in accordance with knownmethods for manufacturing standard aluminum containers. With respect tomanufacturer of the aluminum outer container, the same manufacturingprocess can be used, with the exception that the outer containerconstruction does not include attaching a top lid, and rather, the outercontainer is necked down at the top edge thereof to the same diameter asthe inner container. The outer container is press fit onto the outercontainer. Press fitting the inner container and outer container enablesa friction fit between the sidewall of the inner container and the upperedge of the outer container, and also helps to center the innercontainer so that the nesting configuration can be achieved between therespective domes. As necessary, a sealing or adhesive may be applied toensure that the outer container remains secure to the inner containerwithout slippage or inadvertent displacement. A small opening may bemade in the dome or sidewall of the outer container to allow air toescape as the inner container and outer container are joined to oneanother during the press fit operation. Thereafter, the small openingmay be sealed. In the event an inert gas is to be placed within the gap,this opening can be used to inject the inert gas. With respect to use ofa plastic outer container, the plastic outer container can be made by aninjection or compression molding process to produce a pre-formcomponent. The pre-form component can then be blown in amechanical/pneumatic process to form the final shape of the plasticouter container. The plastic outer container can be embossed, debossed,or otherwise manipulated to register features of the outer containerwith the design printed on the inner can. The plastic outer container istrimmed to a predetermined height. The plastic outer container can thenbe assembled to the inner container. The outer container may be pressedfit onto the inner container if the outer container has already beennecked down at the upper end thereof. Alternatively, the outer containercan be slipped over the inner container, and then localized heating atthe upper portion of the outer container can cause the plastic materialto tightly shrink to the inner container to form a tight seal. Asealing/adhesive compound can also be used to ensure that the outercontainer remains securely attached to the inner container.

Other features and advantages of the present invention will becomeapparent by a review of the following detailed description, taken inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a first embodiment of thepresent invention including an inner aluminum container and an outeraluminum container;

FIG. 2 is a vertical cross-section of the assembled containerillustrating specifically the nested configuration between the domes ofthe inner container and the outer container;

FIG. 3 is an elevation view illustrating the exterior appearance of theassembled container;

FIG. 4 illustrates a cross-sectional view of another embodiment of thepresent invention;

FIG. 5 is an elevation view illustrating the exterior appearance of theembodiment of FIG. 4;

FIG. 6 illustrates another cross-section similar to FIG. 4 but differingin the particular shape of the inner container and the height of theouter container;

FIG. 7 is an elevation view illustrating the exterior appearance of thecontainer of FIG. 6;

FIG. 8 is an exploded perspective view of another embodiment of thepresent invention including an inner container and a polymer/plasticouter container;

FIG. 9 is a cross-section illustrating an assembled container of FIG. 8;

FIG. 10 is an elevation view illustrating the exterior appearance of theembodiment of FIG. 9; and

FIG. 11 is a cross-section illustrating yet another embodiment whereinthe outer container does not have a dome shaped base and rather is flat.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a first embodiment of the present invention inthe form of a double walled beverage container 10. The beveragecontainer 10 comprises two components, namely, an inner container 11,and an outer casing, shell, or outer container 40.

In all of the embodiments, the inner container 11 is preferably astandard aluminum container. The inner container 11 comprises acylindrical shaped sidewall 12, a base 14, an upper neck portion 22, anda top 24. The base 14 is further characterized as including acircumferential or annular concave portion 16, a dome shaped panel 20,and a circumferential/annular leg or protrusion 18. As set forth in, forexample the U.S. Pat. No. 6,098,832, the particular shape of the base ofthe container provides the container with the necessary strength tohouse the beverage therein, and helps to minimize the amount of aluminummaterial used. The >832 patent is hereby incorporated by reference inits entirety herein for disclosing one basic construction for analuminum container, and which is suitable for use in the presentinvention.

The outer container or casing 40 as illustrated has a complementaryshape as the inner container 11. Specifically, the outer container 40also comprises a cylindrical sidewall 42, base 44, circumferentialconcave portion 46, circumferential leg/protrusion 48, and dome shapedpanel 50. The outer container/casing has a slightly larger shape thatenables a nested configuration between the corresponding circumferentialconcave portions of both the inner container and the outer container. Asshown in FIG. 2, the circumferential concave portion 16 of the innercontainer 11 rests on the circumferential concave portion 46 of theouter container 40. Accordingly, a substantially uniform gap is createdbetween the sidewall 12 and the sidewall 42. Through testing, it hasbeen found that providing approximately a ⅛-inch gap between thesidewall 12 and the sidewall 42 provides effective insulation for thebeverage contained within the inner container.

The nested configuration of the respective domes and circumferentialconcave portions effectively centers the inner container within theouter container. As also shown in FIG. 2, there may also be a small gapthat exists between the respective legs 18 and 48, as well as therespective domes 20 and 50. The primary insulation benefit is derivedfrom the spacing of the respective sidewalls of the inner container andthe outer container; however, a gap between the respective domes alsoprovides some amount of additional insulation. It is also contemplatedhowever that domes can be in contact with one another that may providesome additional stability between the inner container and outercontainer and without materially affecting insulation characteristics.

The upper portion of the outer container includes a circumferentialtransition 52 that attaches to the sidewall 12 as shown. The uppertransition 52 tapers to contact the sidewall 12.

FIG. 3 illustrates the exterior appearance of the container of the firstembodiment. Because of the complementary shape of the outer container,along with the relatively small gap between the inner container andouter container, the overall look of the container is essentiallyunchanged, yet the benefit of providing an insulated container isachieved.

The outer container may accept printing, debossing, embossing, or othersurface treatments in order to provide a desired external presentationfor the product.

It shall be understood that with respect to the embodiment of FIG. 1,the outer container 40 can be made of aluminum, or can be made of aplastic polymer. There are a number of plastic materials that can beused including clear monolayer PET, high or low-density polyethylene,PLA, among others. With respect to use of aluminum in the firstembodiment, it is also contemplated that the outer container may be madeof a full thick-walled member. A full thick-walled member refers to thesidewall 42 having a uniform thickness. For many aluminum containers, itis well known to Aneck down@ or thin the aluminum material located atthe midsection of the sidewall in order to save on the amount ofaluminum that is used within the container. Since the outer container isnot under pressure, it is desirable to prevent the outer sidewall fromcollapsing when grasped. Therefore, by constructing the outer sidewallof a full, thick-walled member, the thicker mid-section helps to remedyany tendency of the outer container sidewall to collapse when grasped.

FIGS. 4 and 5 illustrate yet another embodiment of the container 10 ofthe present invention. The reference numbers used in this embodimentcorrespond to the same elements as those set forth in the firstembodiment of FIGS. 1-3. The difference in the embodiment of FIGS. 4 and5 is that there is no nested configuration between the domes of theinner container and the outer container. Rather, the leg 18 of the innercontainer rests on the dome panel 50 of the outer container as shown.This embodiment may be chosen if it is desired to provide a greater gapbetween the inner container and the outer container. In comparing FIGS.3 and 4, there is very little difference in the overall exteriorappearance, the basic cylindrical shape and size of the container beingmaintained.

FIGS. 6 and 7 illustrate yet another embodiment of the presentinvention. The same reference numbers are also used in FIGS. 6 and 7 asin the first embodiment to denote the same structural elements. Theembodiment of FIGS. 6 and 7 is similar to the embodiment of FIGS. 4 and5 in that the leg 18 of the inner container 11 rests on the dome 50 ofthe outer container. FIGS. 6 and 7 differ from the embodiment of FIGS. 4and 5 in that the sidewall 42 of the outer container 40 does not extendas far upwards along the sidewall 12. In the case of FIGS. 6 and 7, theshorter appearing outer container may be a result of simply providing aninner container 11 of a greater height, or reducing the height of theside wall 42 of the outer container 40.

FIGS. 8-10 illustrate another embodiment of the present invention. Inthis embodiment, the same inner container 11 is provided, but the outercontainer 60 is preferably made from a plastic polymer. As shown, theouter container 60 includes a side wall 62, a plurality of spacedannular grooves 64, a neck 66, base 68, a circumferential frusto-conicalconcave portion 70, circumferential leg 72, and dome shaped panel 74.Thus, with respect to the specific shape of the outer container 60, itis very similar to the outer container 40 with the exception that theplurality of annular grooves 64 is formed. FIG. 9 is a cross sectionillustrating the outer container 60 assembled to the inner containerwherein the inner surface of the outer container makes contact with thesidewall 12 at the location of the grooves 64; however a gap ismaintained between the other parts of the outer container and thesidewall 12. Because of the inherent insulative characteristics of someplastic materials, effective insulation may be maintained despite thecontact of the outer container at some locations against the sidewall ofthe inner container. The annular grooves 64 may be provided foraesthetic/ornamental purposes, to increase the strength of the outercontainer, and/or to enhance the ability of a consumer to grip thedouble walled container

Also in accordance with the present invention, a method is provided formanufacturing a double walled container. With respect to the manufactureof an inner aluminum and an aluminum outer container, the innercontainer may be constructed in accordance with known methods formanufacturing standard aluminum containers. As understood by thoseskilled in the art, manufacturing of the inner container comprises anumber of steps to include drawing and ironing a single piece ofaluminum into a desired shape, washing and printing the container,providing any desirable coatings for the interior surface of thecontainer attaching the lid, and then filling. With respect to themanufacture of the aluminum outer container, the outer container isformed from one piece, is drawn and ironed in the same manner as astandard aluminum container. The outer container is then trimmed to apredetermined height, washed, printed, and coated to protect theinterior and exterior surfaces thereof. The upper transition is thenreduced in circumference by roll forming that part of the outercontainer. Preferably, the circumference of the upper transition isprovided such that outer container must be press fit onto the innercontainer. Press fitting the inner container and outer container enablesa friction fit between the side wall and the upper transition, and alsohelps to center the inner container so that the nesting configurationcan be achieved between the respective domes. As necessary, asealing/adhesive compound may be applied to ensure that the outercontainer remains secure to the inner container without slippage ordisplacement. The outer container may be assembled to the innercontainer prior to or after the filling of the inner container with thebeverage.

As mentioned above, the outer container may comprise a full thick-walledpiece of aluminum to prevent the outer container from easily collapsingby a firm grip from the consumer. Additionally, a stronger outercontainer may help to mitigate shipping damage. A small opening may beprovided in the sidewall of the outer container or the dome of the outercontainer to enable air to escape as the inner container and outercontainer are press fit. After the inner container and outer containerhave been assembled, the opening may be sealed. By press fitting theinner container matter outer container, the contact of the outercontainer against the inner container at the location of the transitionshould prevent the container from inadvertently slipping or displacing;however, as mentioned above, an adhesive may be applied to the innercontainer at the location where it contacts the inner surface of thetransition area in order to further ensure that the outer containerremains securely attached to the inner container. If it is desired tofill the gap between the outer container and inner container with eithera solid insulating material such as foam, or with an inert gas, the sameopening through which air is allowed to escape during the press fitoperation may be used to introduce the insulating foam or inert gas.

With respect to use of a plastic polymer outer container in accordancewith the method of the present invention, the plastic outer containercan be made by an injection or compression molding process to produce apreform component. The preform material can then be blown in amechanical/pneumatic process to form the final shape of the outercontainer. The outer container can be embossed or debossed to registerfeatures of the outer container with the printed inner container. Theblown outer container can be trimmed to a predetermined height. Theouter container can then be assembled to the inner container. Localizedheating in the neck portion of the outer container can cause the plasticpolymer to tightly shrink to the inner container to form a tight seal. Asealing/adhesive compound could also be used to ensure that the outercontainer remains securely attached to the inner container.

FIG. 11 shows yet another embodiment of the present invention wherein aplastic outer container is used, and the base 68 of the outer container60 is flat and does not have a dome shape. Thus, no nesting relationshipexists between the base 68 and the base 14 of the inner container.Rather, a gap 80 exists between the base 68 and the base 14.

With respect to use of a plastic polymer outer container, the type ofplastic material, the thickness of the material, and the color of theplastic material may be selected to enhance or modify the visual effectof the printed inner container. For example, the printed color of theinner container along with the chosen color for the outer plastic outercontainer may be combined for a unique visual effect. Further forexample, the particular pattern printed on the inner container may bedistorted by the shape of the outer surface of the outer containerthereby providing a unique visual presentation.

Also, it shall be understood that with all of the embodiments, theparticular height of the sidewall of the outer container can be adjustedin order to provide a desired amount of insulation covering for theinner container. In some circumstances, it may be desirable to reducethe height of the outer container member so that a greater portion ofthe inner container is exposed.

There are a number of advantages to the double walled container of thepresent invention. A simple yet effective means is provided forinsulating a beverage within a standard aluminum container. Theinsulation is provided by an aesthetically pleasing, non-intrusive, andmechanically simple outer container. The outer container may be madefrom a number of materials to include simply a larger sized aluminumcontainer minus the top, or a plastic polymer outer container. Thenested domes create a uniform air gap between the inner container andouter container. The outer container does not substantially change thesize of the inner container. The appearance of the inner container canbe maintained with the plastic outer container, or special visualeffects can be created by use of the outer container.

While the present invention has been described with respect to variouspreferred embodiments, it shall be understood that various other changesand modifications may be made to the invention in accordance with thescope of the claims appended hereto.

What is claimed is:
 1. A double walled container comprising: an innercontainer including a cylindrical sidewall, a base connected to saidside wall and forming a lower portion of the container, and a topforming an upper portion of the container, said base including a domeshaped panel; and an outer container secured to said inner container,said outer container comprising a cylindrical side wall, a base forminga lower portion of the outer container, and an upper transition portionforming an upper end of the outer container, said upper transitionportion contacting said side wall of said inner container, said base ofsaid outer container member including a dome shaped panel; and whereinsaid side wall of said inner container and said side wall of said outercontainer are separated by a substantially uniform gap, and saiddome-shaped panel of said outer container has a curved shape, and saiddome-shaped panel of said inner container has a complimentary curvedshape and spaced uniformly from said dome-shaped panel of said outercontainer.
 2. A container, as claimed in claim 1, wherein: said sidewallof said inner container is spaced approximately ⅛″ from said side wallof said outer container, and wherein said side walls maintain said ⅛″spacing circumferentially around said inner container placed in saidouter container.
 3. A double-walled container comprising: an innercontainer including a sidewall, a base connected to said side wall andforming a lower portion of the container, a top forming an upper portionof the container, said base including a dome-shaped panel; and an outercontainer secured to said inner container, said outer containercomprising a cylindrical side wall and a base forming a lower portion ofthe outer container, and an upper transition portion forming an upperend of the outer container, said upper transition portion contactingsaid sidewall of said inner container, said base of said outer containerincluding a dome-shaped panel, said dome-shaped panel of said outercontainer having a complimentary shape as compared to the dome-shapedpanel of said inner container, and said dome-shaped panels havingsubstantially the same curvatures resulting in a nested configurationbetween said dome-shaped panels, and wherein said side wall of saidinner container and said side wall of said outer container are separatedby a substantially uniform circumferential gap; and said outer containerhaving a cylindrical side wall and a plurality of annular grooves formedon said side wall and spaced from one another along a height of saidinner container.
 4. A method of manufacturing a double-walled container,said method comprising the steps of: drawing and ironing a single pieceof material in a cylindrical shape, including a base and side walls,said base including a circumferential concave portion extendingcircumferentially around said base, a circumferential leg protrudingfrom said circumferential concave portion and disposed radially inwardfrom said concave portion, and a dome-shaped panel spanning between saidcircumferential leg; securing a top to said single piece of aluminum,thereby forming an inner container; molding a plastic outer containerhaving a cylindrical side wall and a base, said base of said outercontainer including a circumferential concave portion extendingcircumferentially around said base, a circumferential leg protrudingfrom said circumferential concave portion and disposed radially inwardfrom said concave portion, and a dome-shaped panel spanning between saidcircumferential leg; forming an upper transition on said outercontainer; placing said outer container over said inner container; andheating said upper transition to shrink it in contact around the innercontainer.
 5. A method, as claimed in claim 4, wherein: said dome ofsaid inner container has a first curvature, and said dome of said outercontainer has a second curvature substantially similar to said firstcurvature, and wherein said domes are placed in a nested configuration.